Scored Package And A Method Of Making The Same

ABSTRACT

The present invention relates to a flexible pouch that is sealed on the sides to provide a space therein for a product. On one end of the pouch may be a recloseable feature. A patterned score line may be provided on an end of the pouch for removing a sheath disposed over the recloseable feature thereby exposing the recloseable feature. The pouch may be utilized for the storage of food products, such as cheese.

FIELD OF THE INVENTION

The present invention relates to a film that is irradiated by a focusedlaser beam to provide a patterned score line on the film. In addition,the present invention relates to a package that may be torn along thescore line. More specifically, the package may have a recloseablefeature to open and then reclose the package, such as, for example, azipper. The score line may allow the package to be opened usingpull-apart forces, thereby exposing the recloseable feature allowing auser of the package to gain access to the interior of the package foritems that may be contained therein.

BACKGROUND OF THE INVENTION

It is generally known for packaging, such as flexible plastic packaging,to hold and/or store products, such as food products. More specifically,it is known for flexible plastic packaging to contain a plurality oflayers wherein each of the layers has one or more features that may beimportant to holding and storing food products contained within thepackaging.

Recloseable features are utilized on flexible plastic packaging to allowan individual to gain access to a product contained therein, and to thenseal the product within the packaging for later use. For example, arecloseable plastic zipper can be incorporated into the plasticpackaging. The plastic zipper typically is attached on an end of thepackaging and utilized to provide an opening in the end of the package.Alternatively, the plastic zipper is attached to inside surfaces of thepackage and is exposed when a portion of the plastic packaging isremoved from the plastic packaging.

The flexible plastic packaging typically is provided with a feature thatallows the portion of the plastic packaging to be removed from theplastic packaging thereby exposing the recloseable feature. This featureis a tear tape or a score line that is incorporated into the packaging.For example, a heat sealable tear tape is heat sealed to an insidesurface of a plastic packaging that is folded and sealed on its sides.The tear tape provides a hermetic seal on the top of the package andfurther allows the top portion of the plastic packaging to be removedfrom the remainder of the package when an end of the tear tape isgripped and pulled so that the tear tape tears across the package.

Of course, a score line is also used to allow the portion of the plasticpackaging to be removed, thereby exposing the recloseable feature. Scorelines can be etched into the plastic packaging by a plurality ofmethods, such as by machine scoring and/or laser scoring of the plasticfilm. For example, plastic packaging is mechanically scored by using ablade that may provide a slight etching in the plastic film to provide aline of weakness in the film so that the portion of the film may be tornfrom the remainder of the packaging using digital pull-apart forces.

A laser beam typically is used to vaporize or otherwise remove a portionof the plastic film to create lines of weakness in the plastic film. Aplastic film is created via coextrusion and/or extrusion or adhesivelamination and proceeds as a flat moving web that is etched by anon-moving laser source to provide a single line of weakness in themachine direction of the web. Of course, a plurality of laser sourcescan be provided to create a plurality of score lines in the machinedirection of the web.

It is further known that a laser beam may create lines of weakness intwo independent directions, as well. For example, U.S. Pat. No.5,001,325 to Huizinga illustrates a multilayer film that may be scoredvia a laser beam in two directions, i.e. the machine direction andtransverse to the machine direction, or, generically, the X and Ydirections on the surface of the film. Scanners typically scan forrecurring patterns on the film and signal for the movement of the laserbeam over the advancing film in the two perpendicular directions.

Packages are known that contain a product, such as, for example, acheese product. A typical package consists of two flat multilayer filmsthat are heat sealed on three sides to provide a compartment therein.For example, a single multilayer film is folded and sealed on its sidesto provide the package. On the fourth side, a resealable feature isprovided for opening and closing the package to add and/or remove theproduct from the package. The recloseable feature is a zipper that opensor closes the package when the slider is moved laterally over the openend of the package. However, the open end of the package containing therecloseable feature must be initially hermetically sealed to keep andstore the product that is contained therein. A typical hermetic seal isprovided below the zipper, which is opened by pull-apart forces when thepackage is opened for the first time.

Alternatively, the zipper is provided on inside surfaces of the package.The outer surfaces of the package therefore extend over the zipper andare hermetically sealed at a position over the zipper thereby providinga sheath over the zipper. Not only does this configuration provide ahermetic seal for the package, but the sheath further protects thezipper. To remove the sheath, score lines or tear tapes are provided sothat the sheath is torn and the zipper exposed. However, the sheath istypically removed below the zipper so as to expose the zipper when thesheath is torn away.

FIG. 1 illustrates a prior art package 500 with a sheath 501 extendingover a zipper 504 and having a one-dimensional score line 502 thatextends horizontally across the sheath 501 at a position below thezipper 504. When the sheath 501 is torn at the score line 502, madeeasier by the use of a notch 506 in the side of the package 500, thezipper 504 is exposed, and the package 500 may be opened or closed bythe zipper 504. However, to tear the sheath 501 below the zipper 504 andremove the sheath 501, thereby exposing the zipper 504, the tracks ofthe zipper 504 cannot extend to the edges of the package 500, or thetracks of the zipper 504 would remain attached to the edges of thesheath 501 and the sheath 501 would not be removable below the zipper504. The opening provided by the zipper 504 is, by necessity, smallerthan the width of the package 500. The opening, therefore, restricts themovement of articles into and out of the package 500. Moreover, thepackage, having a smaller opening than the width of the package, isaesthetically displeasing because it appears that the zipper is sizedincorrectly and does not fit the package.

One way to solve this problem and allow a zipper to extend from one edgeof the package to a second edge of the package is illustrated in FIG. 2,which illustrates a prior art package 600 with a sheath 601 extendingover a zipper 604 and having a one dimensional score line 602 thatextends horizontally across the sheath 601 at a position below thezipper 604. However, the score line 602 is disposed between holes 608that are stamped in the sheath 601. Notches 606 are provided above thezipper 604 to allow the sheath 601 to be torn above the zipper 604 andallow the path of the tear to travel below the zipper 604 and,therefore, across the sheath 601 via the score line 602. A drawback ofthis package, however, is that the sheath 601 would not provide ahermetic seal when sealed over the zipper because of the holes 608 thatare stamped into the sheath 601. Therefore, a hermetic seal 610 isprovided on the inside of the package 600 below the zipper. When theseal 610 is broken by pull-apart forces, the contents of the package areexposed. This packaging system must, however, include the extra steps ofstamping the holes in the sheath, and providing the hermetic heat sealon the inside surfaces of the package. In addition, the film necessarilyneeds a heat sealable film at the specific location below the zipper sothat the walls of the package can be heatsealed together.

A need exists, therefore, for a package that includes a recloseablefeature, such as a zipper, that is protected by a hermetically sealedsheath. Moreover, the recloseable feature should be provided across anentire width of the package, and the sheath should be removable from thepackage, thereby exposing the recloseable feature. A need further existsfor a package that does not need a hermetic seal across a width of thepackage below the recloseable feature.

SUMMARY OF THE INVENTION

The present invention relates to a package that is sealed on three sidesand recloseable on a fourth side. The recloseable feature may be arecloseable zipper that may extend over an entire width of the package.The outside surface of the package extends over the recloseable featureand is hermetically sealed above the recloseable feature therebyproviding a sheath over the recloseable feature. The sheath is torn froma remainder of the package using digital pull-apart forces. When torn bydigital pull-apart forces, the sheath may initially tear above therecloseable feature and the tear may proceed below the recloseablefeature across almost the entire width of the package following atwo-dimensional score line in the outside surfaces of the package. Thisscore line may, therefore, allow the sealed edges of the recloseablefeature to remain clear of the removable portion of the sheath.

To this end, in an embodiment of the present invention, a package isprovided comprising a first side wall; a second side wall wherein thefirst side wall and the second side wall are bonded together on edges toform a pouch having a space therein for storing a product; a recloseablefeature disposed on inside surfaces of the side walls wherein the sidewalls are sealed together on an end of the package; and a score line inat least one side wall from a first edge to a second edge of the atleast one side wall wherein the score line traces a path from above therecloseable feature at said first edge to below the recloseable featurebetween the edges when the pouch is oriented such that the recloseablefeature is on a top side of the pouch.

In an alternate embodiment of the present invention, a package for aproduct is provided comprising a first side wall; a second side wallwherein the first side wall and the second side wall are bonded togetheron edges to form a pouch having a space therein for storing a product; arecloseable feature on an end of the package; a sheath disposed over therecloseable feature wherein the sheath has a first end, a second end,and side edges, and further wherein a first end of the sheath isintegrally attached to the side walls of the package; and a score linein the sheath from a first edge to a second edge of the sheath whereinthe score line traces a path from above the recloseable feature at theedges to below the recloseable feature between the edges when the pouchis oriented such that the recloseable feature is on a top side of thepouch.

In a further embodiment of the present invention, a package for productsis provided comprising a pouch comprising side walls having a seal onall sides to form a space for retaining a product; a recloseable featuredisposed near one of the sealed sides of the pouch wherein therecloseable feature is sealed to inside surfaces of the pouch andfurther wherein the side walls extend over the recloseable feature; anda score line in at least one side wall from a first edge to a secondedge of the at least one side wall wherein the score line traces a pathfrom above the recloseable feature at the side edges to below therecloseable feature between the side edges when the pouch is orientedsuch that the recloseable feature is on a top side of the pouch.

In an alternate embodiment of the present invention, a method of makinga package is provided comprising the steps of providing a first wall anda second wall; scoring a score line in at least one side wall; providinga recloseable feature attached at a first end of the side walls;attaching the recloseable feature to inside surfaces of the side walls;and sealing the first wall and the second wall together on edges of thewalls to form a pouch having a space therein for a product, wherein saidscore line is disposed above the recloseable feature at edges of theside walls and further wherein said score line traces a path to belowthe recloseable feature between the edges of the side walls.

Still further, in an alternate embodiment of the present invention, amethod of making a package is provided comprising the steps of providinga sheet of a flexible film material; providing a score line in the sheetof flexible film material; sealing a first side of a recloseable featureto the flexible film material; folding the sheet and sealing the sheeton side edges of the sheet to form a pouch having a space therein for aproduct wherein the pouch has an open end; sealing a second side of therecloseable feature to the flexible film material; filling the pouchwith product; and sealing the open end of the pouch, wherein the scoreline is disposed in the sheet of flexible film material from a first toa second edge of the pouch wherein the score line traces a path fromabove the recloseable feature at the edges of the pouch to below therecloseable feature between the edges of the pouch when the pouch isoriented such that the recloseable feature is on a top side of thepouch.

And finally, in a still further alternate embodiment of the presentinvention, a method of using a package is provided comprising the stepsof providing a package comprising a pouch having a product containedtherein wherein said pouch has a recloseable feature on an end of thepouch and further wherein side walls of said pouch extend over therecloseable feature and further wherein said pouch has a score linedisposed in the package from a first edge of the package to a secondedge of the package wherein the score line traces a path from above therecloseable feature at the side edges of the package to below therecloseable feature between the side edges of the package; and tearingsaid package along said score line to gain access to said pouch.

It is, therefore, an advantage of the present invention to provide apackage that may keep and store a product, such as a product that mayhave a limited shelf-life. For example, the product may be a foodproduct, such as cheese. The package may be hermetically sealed on allsides and may further restrict the movement of moisture and/or oxygenthrough the walls of the package, thereby keeping the product containedtherein fresh.

In addition, it is an advantage of the present invention to provide apackage having a recloseable feature on an end of the package so thatfood products may be stored and kept within the package after thehermetic seal on the package has been broken when the package isinitially used by an individual attempting to retrieve the productcontained therein. It is further advantageous that a sheath is providedthat extends over the recloseable feature that may provide the hermeticseal on the package and further protect the recloseable feature.

Still further, it is an advantage of the present invention to provide atwo-dimensional score line on the package that may allow the sheath tobe removed, thereby exposing the recloseable feature. The score line mayallow the sealed ends of the recloseable feature to remain clear of theremovable portion of the sheath.

Additional features and advantages of the present invention aredescribed in, and will be apparent from, the detailed description of thepresently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a plan view of a prior art package having a zipperthat does not extend to the edges of the package and a one-dimensionalscore line provided across the package.

FIG. 2 illustrates a plan view of a prior art package having a zipperextending to the edges of the package and a one dimensional score lineprovided across the package with holes stamped in the package to directthe tearing of the package.

FIG. 3 illustrates a plan view of a flexible pouch having a zipper andfurther having a patterned score line provided on the flexible pouch inan embodiment of the present invention.

FIG. 4 illustrates a cross-sectional view along lines IV-IV of theflexible pouch showing the score lines and the zipper in an openconfiguration in an embodiment of the present invention.

FIG. 5 illustrates a cross-sectional view along line V-V of the flexiblepouch showing the score lines and the zipper in a closed configurationin an embodiment of the present invention.

FIG. 6 illustrates a plan view of a flexible pouch having a zipper andfurther having a patterned score line in an alternate embodiment of thepresent invention.

FIG. 7 illustrates a cross-sectional view along line VII-VII of theflexible pouch in the alternate embodiment of the present invention.

FIG. 8 illustrates a plan view of a flexible pouch having a zipper andfurther having a patterned score line in an alternate embodiment of thepresent invention.

FIG. 9 illustrates a cross-sectional view along line IX-IX of theflexible pouch in the alternate embodiment of the present invention.

FIG. 10 illustrates a plan view of a flexible pouch havingtwo-dimensional score lines therein being torn by digital pull-apartforces in an embodiment of the present invention.

FIG. 11 illustrates a plan view of a flexible pouch without the sheathand with the zipper exposed in an embodiment of the present invention.

FIG. 12 illustrates a cross-section of a package along line XII-XII inan embodiment of the present invention.

FIG. 13 illustrates a plan view of a flexible pouch having a zipper andfurther having a two-dimensional score line provided on the flexiblepouch in an alternate embodiment of the present invention.

FIG. 14 illustrates a cross-sectional view along line XIV-XIV in analternate embodiment of the present invention.

FIG. 15 illustrates a cross-sectional view along line XV-XV in analternate embodiment of the present invention.

FIG. 16 illustrates a plan view of a flexible pouch without the sheathin an alternate embodiment of the present invention.

FIG. 17 illustrates a cross-sectional view along line XVII-XVII in analternate embodiment of the present invention.

FIGS. 18A-18H illustrates a preferred method of making a flexible pouchhaving a zipper and a patterned score line in an embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

The present invention relates to a flexible pouch that is sealed on thesides to provide a space therein for a product. On one end of the pouchmay be a recloseable feature. A patterned score line may be provided onan end of the pouch for removing a sheath disposed over the recloseablefeature thereby exposing the recloseable feature. The pouch may beutilized for the storage of food products, such as cheese or any otherproduct that may be apparent to one having ordinary skill in the art.

Now referring to the figures, wherein like numerals refer to like parts,FIG. 3 illustrates a food pouch 1 in an embodiment of the presentinvention. The food pouch 1 may have two side walls 10, 12 (as shown inFIGS. 4 and 5) made from multilayer flexible film that are heat sealedtogether to form a space 14 wherein a food product 16, or any otherproduct 16, may be stored. The food product may preferably be a dairyproduct, such as a cheese product, that may be stored within the pouch1.

The edges of the side walls 10,12 are heat sealed together to form seals18, 20, 22 and 24. The seals may be hermetically sealed to provide abarrier for the movement of oxygen or moisture through the edges of thepouch 1. On one end 28 of the pouch 1 may be provided a recloseablefeature that may preferably comprise a zipper system 30. Of course,however, other recloseable features may be utilized in this inventionwithout detracting from the present invention. The zipper system 30 maycomprise a first zipper portion 32 that is bonded to an inside surfaceof the side wall 10. In addition, the zipper system 30 may comprise asecond zipper portion 34 that is bonded to an inside surface of the sidewall 12.

The first zipper portion 32 may comprise a zipper track portion 36 thatis attached to a film extender 38. The film extender 38 may be attachedto the inside surface of the side wall 10 at seal 40. Similarly, thesecond zipper portion 34 may comprise a zipper track portion 42 that isattached to a film extender 44. The film extender 44 may be attached tothe inside surface of the side wall 12 at seal 46. The seals 40,46 mayextend over an entire width of the pouch 1, including within the seals20,24. The zipper track portions 36,42 may be connectable together whena slider 48 is moved along tracks that may be provided on the zippertrack portions 36,42. The slider 48 may close the zipper track portions36,42 together to form a tight seal between the seals 20,24, as shown inFIG. 5.

FIG. 4 illustrates a cross-section of the pouch 1 along line IV-IVshowing the side walls 10,12 sealed together at seals 18,22 andproviding a space 14 therein for a food product 16. The zipper portions32,34 of the zipper system 30 are shown heat sealed to the insidesurfaces of the side walls 10,12, respectively. The zipper trackportions 36,42 are shown open.

FIG. 5 illustrates a cross-section of the pouch 1 along line V-V showingthe side walls 10,12 heat sealed together at seals 18,22 and providing aspace 14 therein for a food product 16. The zipper portions 32,34 of thezipper system 30 are shown sealed to the inside surfaces of the sidewalls 10,12, respectively. The zipper track portions 36,42 are shownclosed.

Still referring to FIG. 3, a score line 50 is provided in at least oneof the side walls 10,12. In a preferred embodiment, the score line 50may be provided in both of the side walls 10,12. The score line 50 mayhave a first curved portion 52 a that may start on an edge of the pouch1 and be disposed above the zipper track portions 36,42, when the pouchis oriented so that the zipper system 30 is at the top of the pouch 1.The curved portion 52 a may trace a path that travels below the zippertrack portions 36,42 until the curved portion 52 a meets a generallystraight portion 52 b that traces a path across the face of the pouch 1until the score line 50 reaches the proximity of the other end of thepouch 1. The score line 50 then meets a second curved portion 52 c thattraces a path from below the zipper track portions 36,42 to above thezipper track portions 36,42 to the edge of the pouch 1. Of course, thescore line 50 may be any shape that may be apparent to one havingordinary skill in the art including tracing a path that goes below andabove the zipper track portions 36,42 a plurality of times between theends of the pouch 1. To facilitate the tearing of the score line 50 whendigital pull-apart forces are applied, notches 54,56 may be provided onedges of the pouch to allow a tear to form in the side walls when pulledby digital pull apart forces.

The score line 50 is provided in the side wall 10 and/or 12 so as toallow an individual to grip the end 28 of the pouch 1 and tear the end28 from the pouch 1 along the path of the score line 50. Because thezipper track portions 36,42 extend from one edge of the pouch 1 to theother edge of the pouch 1, the portion of the pouch 1 that is removedmust clear the portions of the zipper track portions 36,42 that are heatsealed within the heat seals 20,24. However, the portion of the pouch 28that is removed extends below the zipper track portions 36,42 so as toallow an individual to have easy access to the slider 48 to move theslider 48 back and forth along the zipper track portions 36,42.

The score line 50 may be scored via, preferably, a laser beam, or anyother means apparent to one having ordinary skill in the art. The scoreline has a tensile value measured across the line of weakness of betweenabout 3 and about 10 lbs/in. Preferably, the score line 50 has a tensilevalue measured across the line of weakness of about 6.5 lbs/in.

FIG. 6 illustrates an alternate embodiment of the present invention of apackage 60 having the zipper system 30 and the score line 50, asdescribed above with references to FIGS. 3-5. In addition, the package60 includes the seals 18, 20 and 24. However, the package 60 does notinclude the seal 22, as shown in FIGS. 3-5. Instead, the walls of thepackage 60 may be constructed from a single sheet of flexible film andfolded at fold 62, thereby providing a closed end on the package 60without sealing the inside surfaces of the film together. FIG. 7illustrates a cross section of the package 60 through line VII-VIIshowing the fold 62 on the end of the package 60. Of course, the package60 may be sealed at the folded end of the package 60 to provide stiffercharacteristics, such as if a hole is punched into the folded end of thepackage 60 to allow the package to hang on a hook for display purposesin a supermarket, for example.

In a preferred embodiment of the present invention, a package 70 isshown in FIG. 8. The package 70 may be constructed like the package 60shown in FIGS. 7-9 by a single sheet of flexible film that is folded atfold 72 and sealed to form seals 20, 22 and 24 on the other three sidesof the package 70. The zipper system 30, however, may be provided nearthe end of the package 70 having the fold 72. Of course, the folded endof the package 70 may further have a seal to provide stiffercharacteristics at the folded end of the package 70, such as if a holeis punched in the end of the package for hanging the package 70 fordisplay purposes.

FIG. 10 illustrates the digital removal of the end 28 from the pouch 1along the score line 50. As shown in FIG. 12, the removal of the end 28exposes the zipper track portions 36,42 and the zipper slide 48 so thatthe zipper slide 48 may be slid along the zipper track portions 36,42thereby opening or closing the pouch 1 to gain access to the product 16contained therein.

FIG. 13 illustrates an alternate embodiment of a pouch 100 of thepresent invention. The pouch 100, similar to the pouch 1 as illustratedin FIG. 3, may be formed from two side walls 110,112 that may be heatsealed together along the edges of the side walls to form heat seals 120a, 122 and 124 a. As stated above with reference to FIGS. 6-9, the pouch100 may also be comprised of a single sheet of flexible film that isfolded in half and sealed along the edges of the flexible film to formthe pouch 100 having a space 114 therein for a product 116 to becontained therein.

On ends of the side walls 110,112 may be zipper track portions 136,142that may be sealed or unsealed together via a zipper slide 148. Thezipper track portions 136,142 may extend from one end of the pouch 100to the other end of the pouch 100.

A sheath 150 is disposed over the zipper track portions 136,142 and maybe heat sealed to outer surfaces of the side walls 110,112 via heatseals 140,146. The sheath 150 may be comprised of two flexible filmsheets 152, 154 wherein each of the flexible film sheet 152 and 154 areheat sealed to the outer surfaces of the side walls 110,112,respectively. The sheath 154 may have heat seals 120 b, 124 b on two ofthe edges of the sheath 150. In addition, the sheath 150 may have an endseal 160. Alternatively, the sheath 154 may be a single sheet offlexible film that is folded at heat seal 160 and heat sealed to theouter surface of the side walls 110,112.

As in pouch 1, a score line 150 is cut into one or both sides of thesheath 150. The score line 150 may comprise a first curved portion 152a, a straight portion 152 b that may trace a path from almost one end ofthe pouch to the other and may be disposed below the zipper trackportions 136,142 when the zipper track portions 136,142 are oriented atthe top of the pouch 100. The score line 150 may have a second curvedportion 152 c at a second edge of the pouch 100. Of course, any othershaped score line may be provided according to someone having ordinaryskill in the art. When the sheath 150 is gripped and pulled usingdigital pull-apart forces, the sheath 154 tears along the score line 150and provides access to the zipper track portions 136,142 and the zipperslide 148. However, the curved portions allow the sheath to clear theedges of the zipper track portions 136,142 that may be sealed in theheat seals 120 b, 124 b.

Still referring to FIG. 13, when the sheath 154 is gripped and pulledusing digital pull-apart forces, the score line 150 may tear along firstcurved portion 152 a, the straight portion 152 b, and the second curvedportion 152 c to form a package 200, as shown in FIGS. 16 and 17. Thepackage 200 may have a portion of the sheath 154 torn away and may leavesheath portions 202 a, 202 b. The zipper track portions 136,142 may berevealed allowing an individual to gain access to the interior space 114of the package 200. The zipper track portions 136,142 may be closeableand openable via a slider 148. Alternatively, the zipper track portions136,142 may be closeable and openable in any way as may be apparent toone having ordinary skill in the art.

The packages of the present invention may be made from any flexible filmmaterial as may be apparent to one having ordinary skill in the art. Theouter walls 10,12, as shown in FIG. 3 and outer walls 110,112, as shownin FIG. 13, may be multilayer films having individual layers used fortheir particular properties. For example, the outer layer of the pouch 1or pouch 100 may be any conventional oriented film to provideabuse-resistance to the package and that may be easily scored via alaser, such as, for example, oriented polyester (PET) biaxially orientednylon (BON), or oriented polypropylene (OPP). The inner layers of themultilayer film may be polyolefin based and/or foil such that a laserthat may be utilized to cut a score line in the film may be mosteffective on the outer layer, yet allow the inner layer to remainrelatively untouched. In addition, there may be barrier layers containedwithin the multilayer structures that may provide a barrier againstoxygen and moisture from entering the space 14 of 114 of the pouch 1 or100. The barrier material may be ethylene vinyl alcohol copolymer,polyvinylidene chloride-methyl acrylate copolymer, metal foil,metallized film, or any other barrier material apparent to one havingordinary skill in the art.

The inner layers of the flexible films (i.e. the layers that are heatsealed and/or come into contact with the product contained therein, maybe any polymeric film material that may be apparent to one havingordinary skill in the art for the sealing of the flexible film to itselfor to another film. Typical materials that may be utilized for the heatsealing layer may be low density polyethylene (LDPE), linear low densitypolyethylene (LLDPE), very low density polyethylene (VLDPE), ethylenevinyl acetate copolymer (EVA), ethylene methyl acrylate copolymer (EMA),single site or metallocene catalyzed polyethylene, or ionomer. Inaddition, the sheath 154, as shown in FIG. 13, may be made from the samematerial as the outer walls 110,112. Alternatively, the sheath 154 mayhave a different structure, as may be apparent to one having ordinaryskill in the art.

The score lines 50,150 may be cut into the pouches 1,100 via a focusedlaser beam that may score the film in both the machine direction and thetransverse direction to form a patterned score line. Typically, a laserbeam that may cut film in this manner is directed by a mirror that maybe moved via an actuator. Of course, any method of directing the laserbeam may be utilized as may be apparent to one having ordinary skill inthe art. The laser beam may cut the first curved section 52 a, 152 a ofpouches 1,100, respectively, followed by the straight portions 52 b, 152b, followed by the second curved portions 52 c, 152 c. Further, thelaser beam may cut a web of flexible film after the film has beenextruded and/or laminated. Preferably, the multiple layers of theflexible film are coextruded and/or laminated, and the flexible film isslit and flattened into a sheet. The laser beam is then applied to asurface of the web to score the web in both the machine and transversedirections.

Each individual sheet portion 256, having score lines 250 cut therein bythe laser beam, may be converted into the pouch 60, as shown in FIGS.18A-18H. FIG. 18A shows a flexible film sheet 240 with laser scoresthereon. The sheet 240 may have recurring patterns 242 thereon that aida computer to precisely score the sheet 250 via the laser beam, or otherscoring means. For example, the recurring patterns 242 indicate to acomputer where and when to start cutting into the sheet 240 via thelaser beam. The sheet 240 further has score lines 250 cut thereinto. Thescore lines 250 may be cut into both ends of the sheet 240 and mayinclude recurring patterns of first curved portions 252 a, straightportions 252 b and second curved portions 252 c. Of course, the scorelines 250 may be cut into only one end of the sheet 240 as may beapparent to one having ordinary skill in the art. In addition, the laserbeam that cuts the score lines 250 in the sheet 240 may move in twoindependent perpendicular directions to provide a patterned score linethat is curved. The laser beam can cut the score line 250 into the sheet240 without refocusing itself because the distance between the start ofthe first curved portion 252 a or the second curved portion 252 c andthe straight portion 252 b is a short distance, preferably about 0.75inches.

The sheet 240 may then have the zipper system 30 added to a side of thesheet 240 on a first end of the sheet 240, as shown in FIG. 18B. Thezipper system 30 may be sealed to the side of the sheet 240 by theapplication of heat to the zipper system 30 at heat seal 243. The sheet240 may be folded along line 241 and the corresponding ends of the sheet240 may be aligned, as shown in FIG. 18C. The two ends of the sheet 240should be aligned precisely so that the score lines on each end of thesheet 240 are aligned. Heat is then applied to the zipper system 30 toseal the zipper system to the other end of the sheet 240 when the otherend of the sheet 240 is aligned with the first end of the sheet 240.Moreover, heat is applied across the sheet 240 to seal the two ends ofthe sheet 240 together along heat seals 244, as shown in FIG. 18D. Theheat seals 244 may be aligned with the patterns 242.

The sheet 240 may then be cut at the heat seals 244 by a blade, or anyother means apparent to one having ordinary skill in the art, as shownin FIG. 18E to provide individual packages 246 having an open end 248 ofthe package 246. Each individual package 246 may then be filled withproduct 16 through the open end 248. The open end 248 may then be sealedto provide a package 246 folded on one side and sealed on the otherthree sides, with a recloseable zipper and a patterned score linethereby allowing the end of the package 246 to be removed when digitalpull apart forces are applied to the package 246 along the score line.

EXAMPLE 1

A package is constructed with a film having a first outer layer of 48gauge oriented polyester, a second layer of low density polyethylene, athird layer of polyethylene, a fourth layer of a tie material, a fifthlayer of a barrier material of ethylene vinyl alcohol, a sixth layer ofa tie material, and seventh layer of a heat sealing polyethylene createdby a single site catalyzed reaction. The above-identified seven layerstructure may be coextruded and/or laminated together to form a flexiblefilm that may be utilized to make the packages as described above. Thescore line provided in the film may be scored via a laser beam, creatinga score line having a tensile value measured across the line of weaknessof 6.5 lbs/in. The scored package is delivered as a wound roll to afilling line, such as a conventional horizontal form/vertical fillmachine, such as a Bodolay, Bossar, Laudenberg, Klockner Bartelt. Theempty package would then be formed, filled with a product, andhermetically sealed.

EXAMPLE 2

A package may be formed of a film having substantially the same filmstructure as shown above, but with 60 gauge biaxially oriented nyloninstead of 48 gauge oriented polyester.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. It is, therefore, intendedthat such changes and modifications be covered by the appended claims.

1. A package for a product comprising: a first side wall; a second sidewall wherein the first side wall and the second side wall are bondedtogether on edges to form a pouch having a space therein for storing aproduct; a recloseable feature disposed on inside surfaces of the sidewalls wherein the side walls are sealed together on an end of thepackage; and a score line in at least one side wall from a first edge toa second edge of the at least one side wall wherein the score linetraces a path from above the recloseable feature at said first edge tobelow the recloseable feature between the edges when the pouch isoriented such that the recloseable feature is on a top side of thepouch.
 2. The package of claim 1 wherein the recloseable feature is arecloseable zipper.
 3. The package of claim 1 wherein the package ishermetically sealed on all sides.
 4. The package of claim 1 furthercomprising a notch in the first edge of the at least one side wall atthe score line.
 5. The package of claim 1 wherein said recloseablefeature extends from the first edge of said side walls to the secondedge of said side walls.
 6. The package of claim 1 wherein saidrecloseable feature has side edges wherein said side edges of saidrecloseable feature are integrally sealed to said side edges of saidside walls.
 7. The package of claim 1 wherein the first side wall andthe second side wall are formed from a single piece of film and areconnected together on a first side of the package via a fold.
 8. Thepackage of claim 7 wherein the recloseable feature is disposed near anend of the pouch and further wherein the fold is on an opposite end ofthe pouch from the recloseable feature.
 9. The package of claim 7wherein the recloseable feature is disposed near an end of the pouch andfurther wherein the fold is on the same end of the pouch as therecloseable feature.
 10. A package for a product comprising: a firstside wall; a second side wall wherein the first side wall and the secondside wall are bonded together on edges to form a pouch having a spacetherein for storing a product; a recloseable feature on an end of thepackage; a sheath disposed over the recloseable feature wherein thesheath has a first end, a second end, and side edges, and furtherwherein a first end of the sheath is integrally attached to the sidewalls of the package; and a score line in the sheath from a first edgeto a second edge of the sheath wherein the score line traces a path fromabove the recloseable feature at the edges to below the recloseablefeature between the edges when the pouch is oriented such that therecloseable feature is on a top side of the pouch.
 11. The package ofclaim 10 wherein the recloseable feature is a recloseable zipper. 12.The package of claim 10 wherein the package is hermetically sealed onall sides.
 13. The package of claim 10 further comprising a notch in thefirst edge of the package at the score line.
 14. The package of claim 10wherein said recloseable feature extends from the first edge of saidside walls to the second edge of said side walls.
 15. The package ofclaim 10 wherein said recloseable feature has side edges wherein saidside edges of said recloseable feature are sealed to said side edges ofsaid side walls.
 16. The package of claim 10 wherein the first side walland the second side wall are formed from a single piece of film and areconnected together on a first side of the package via a fold.
 17. Thepackage of claim 16 wherein the recloseable feature is disposed near anend of the pouch and further wherein the fold is on an opposite end ofthe pouch from the recloseable feature.
 18. The package of claim 16wherein the recloseable feature is disposed near an end of the pouch andfurther wherein the fold is on the same end of the pouch as therecloseable feature.
 19. A package for products comprising: a pouchcomprising side walls having a seal on all sides to form a space forretaining a product; a recloseable feature disposed near one of thesealed sides of the pouch wherein the recloseable feature is sealed toinside surfaces of the pouch and further wherein the side walls extendover the recloseable feature; and a score line in at least one side wallfrom a first edge to a second edge of the at least one side wall whereinthe score line traces a path from above the recloseable feature at theside edges to below the recloseable feature between the side edges whenthe pouch is oriented such that the recloseable feature is on a top sideof the pouch.
 20. The package of claim 19 wherein the recloseablefeature is a recloseable zipper.
 21. The package of claim 19 wherein thepackage is hermetically sealed on all sides.
 22. The package of claim 19further comprising a notch in the first edge of a side wall at the scoreline.
 23. The package of claim 19 wherein said recloseable featureextends from the first edge of said side walls to the second edge ofsaid side walls.
 24. The package of claim 19 wherein said recloseablefeature has side edges wherein said side edges of said recloseablefeature are integrally sealed to said side edges of said side walls. 25.The package of claim 19 wherein the side walls are formed from a singlepiece of film and are connected together on a first side of the packagevia a fold.
 26. The package of claim 25 wherein the recloseable featureis disposed near an end of the pouch and further wherein the fold is onan opposite end of the pouch from the disposable feature.
 27. Thepackage of claim 25 wherein the recloseable feature is disposed near anend of the pouch and further wherein the fold is on the same end of thepouch as the recloseable feature.
 28. A method of making a packagecomprising the steps of: providing a first wall and a second wall;scoring a score line in at least one side wall; providing a recloseablefeature attached at a first end of the side walls; attaching therecloseable feature to inside surfaces of the side walls; and sealingthe first wall and the second wall together on edges of the walls toform a pouch having a space therein for a product, wherein said scoreline is disposed above the recloseable feature at edges of the sidewalls and further wherein said score line traces a path to below therecloseable feature between the edges of the side walls.
 29. A method ofmaking a package comprising the steps of: providing a sheet of aflexible film material; providing a score line in the sheet of flexiblefilm material; sealing a first side of a recloseable feature to theflexible film material; folding the sheet and sealing the sheet on sideedges of the sheet to form a pouch having a space therein for a productwherein the pouch has an open end; sealing a second side of therecloseable feature to the flexible film material; filling the pouchwith product; and sealing the open end of the pouch, wherein the scoreline is disposed in the sheet of flexible film material from a first toa second edge of the pouch wherein the score line traces a path fromabove the recloseable feature at the edges of the pouch to below therecloseable feature between the edges of the pouch when the pouch isoriented such that the recloseable feature is on a top side of thepouch.
 30. A method of using a package comprising the steps of:providing a package comprising a pouch having a product containedtherein wherein said pouch has a recloseable feature on an end of thepouch and further wherein side walls of said pouch extend over therecloseable feature and further wherein said pouch has a score linedisposed in the package from a first edge of the package to a secondedge of the package wherein the score line traces a path from above therecloseable feature at the side edges of the package to below therecloseable feature between the side edges of the package; and tearingsaid package along said score line to gain access to said pouch.